Surface_Power_Equipment_System_ESP_Operation.pdf

Surface Power Equipment

1. Hari Utomo
Surface Power System :
Empower ESP Operation

2. Overview
The surface power system serves as the backbone of downhole operations , providing the
essential electrical infrastructure needed to power and control downhole equipment efficiently and
effectively. It plays a critical role in various oil and gas production processes, ensuring the seamless
operation of equipment such as Electrical Submersible Pumps (ESPs), Rod Pumps, Hydraulic
Pumps, and Artificial Lift systems. Without reliable surface power systems, downhole operations
would be prone to inefficiencies, downtime, and safety risks. Therefore, investing in robust surface
power systems is essential for optimizing production, maximizing efficiency, and ensuring the safety
and reliability of downhole operations in the oil and gas industry.

3. Key Component of ESP Operation
Surface Power
Diesel Engine
Transformer
Switchgear
PowerSave
VSD Panel / Control Systems
Junction Box

4. Power Cables: Transmit
electrical power from the
surface equipment to the
downhole ESP motor.
Key Component of ESP Operation
Surface Power
Diesel
Engine
Power Grid
Switch Gear VSD Panel Step-Up Trafo ESP Motor
The prime mover that provides
Mechanical power to drive the
ESP pump. It can be a diesel
engine or an electric motor,
depending on the power
source available at the wellsite.
control the speed and torque of the ESP
motor, allowing for optimization of pump
performance and energy efficiency. The
VSD adjusts the frequency and voltage
of the electrical supply to the motor..
Used to step up or step down the
voltage of the electrical supply to
match the requirements of the ESP
motor.
Electrical ESP Motor typically three-
phase induction motors, also contain
additional component such as
downhole sensors

5. Horse Power (HP) = Power(kW) * Efficiency * 1.73 * PF
0.746
Sizing Power Surface System
•Power (kW) is the power in kilowatts.
•Power (HP) is the power in horsepower.
•Efficiency is the efficiency of the motor (usually expressed as a
decimal, e.g., 0.85 for 85% efficiency).
•0.746 is the conversion factor from horsepower to kilowatts.

6. Categorization Component By Voltage
1.Low Voltage (LV) Components:
1.Typically operates at voltages up to 1,000 volts (V).
2.Includes components such as switchboards, motor
controllers, and power distribution panels.
2.Medium Voltage (MV) Components:
1.Operates at voltages ranging from 1,000 V to 35,000 V.
2.Includes components such as medium voltage
transformers, switchgears, and motor control centers .
3.High Voltage (HV) Components:
1.Operates at voltages above 35,000 V.
2.Includes components such as high voltage transformers,
circuit breakers, and surge arresters.

7. Key Component of ESP Operation
Surface Power
Diesel Engine
Transformer
Synchronizer
PowerSave
VSD Panel / Control Systems
Junction Box

8. Diesel Engine
Radiator & Cooling
System
Exhaust System
Electrical Panel
Alternator
Diesel Engine
Fuel Tank & Base
Frame
Control Panel
Diesel Engine Component:
•Diesel Engine
•Alternator
•Exhaust
•Radiator & Cooling
•Control Panel
•Electrical Panel

9. Benefits of using Diesel Engine
•No Electrical Grid
•Power outage
Backup Power
•Power medical devices in disaster area
Emergency Response Situation
•Outdoor events
•Prime Power to Artificial lift or remote work site
Temporary power source

10. How Diesel Engine Works
https://www.traknus.co.id/news/category/article/genset-recommendations-
for-various-needs

11. Types of Genset
Open Type Silent Type

12. Sizing a Generator
D.O.L to KVAS.D to KVA KVA Used
When
Running
Size (Note 1)Size (Note 2)(Note 3)
1 0.75 2.5 2 1
1.5 1.1 3.75 3 1.5
2 1.5 5 4 2
3 2.2 7.5 6 3
4 3 10 8 4
5 3.7 12.5 10 5
6 4.5 15 12 6
7.5 5.5 18.75 15 7.5
10 7.5 25 20 10
12.5 9.3 31.25 25 12.5
15 11 37.5 30 15
20 15 50 40 20
25 19.6 60.5 50 25
30 22 75 60 30
40 30 100 80 40
50 37 125 100 50
60 45 150 120 60
75 55 187.5 150 75
100 75 250 200 100
125 90 312.5 250 125
150 110 375 300 150
175 130 437.5 350 175
200 150 500 400 200
250 185 625 500 250
300 225 750 600 300
400 300 1000 800 400
Electric Motor SizeMinimum Generator Req’d
(KVA) by Starting Method
Run Power
 HP KW
•Too small a generator will cause voltage fluctuations and damage to the
generator or equipment windings.
•Too large a generator will cause engine to glaze and carbon up, due to
engine loading
Rule of Thumb
Note 1 D.O.L.–Direct On line starting (high current starting).
Note 2 S.D.–Star Delta (smooth starting med- high current).
Note 3–A dummy load or extra load will need to be applied to avoid glazing once
running.
•One horse power (1 hp) equals 0.75 kilowatt i.e. 20hp x 0.75 = 15kW
•Warm generator up before applying load
•Always engage load from largest to smallest
•Have an electrician balance the load across all phases for single phase loads
•When motor is operating, after start, requirement will be 1kva for 1hp i.e. 20hp –
20kva used when running.
•Size the generator to run between 60-80% full load rating of generator
•Amps available on a generator per phase = kvax 1.39. i.e. 20kva = 28amps/phase
over 3 phases.
https://www.nationalpump.com.au/calculators/guide-to-choosing-
generator-to-motor-size/

13. Key Component of ESP Operation
Surface Power
Diesel Engine
Transformer
Synchronizer
PowerSave
VSD Panel / Control Systems
Junction Box

14. Power Transformer
•A transformer is a static machine used for transforming power
from one circuit to another without changing frequency. Power
Transformers refer to the transformers used between the generator
and the distribution circuits, and these are usually rated at 500 kVA
and above.
•Types of Power Transformers:
•Small power transformers: 500 to 7500 kVA
•Medium power transformers: 7500 KVA to 100 MVA
•Large power transformers: 100 MVA and above.

15. Working Principle

16. Components
•Core: The central part of the transformer, made up of laminated
steel to carry the magnetic flux.
•Coil: Wound with copper or aluminum wire, these are the primary
and secondary windings that carry the electrical energy.
•Insulation: Materials used to electrically isolate different parts of
the transformer and to contain the transformer oil.
•Tap Changer: A device to adjust the transformer’s output voltage
by changing the turns ratio.
•Conservator Tank: A part of the transformer’s cooling system
that compensates for oil expansion and contraction due to
temperature changes.
•Cooling System: Includes components like radiators, fans, or
pumps to control the temperature of the transformer oil and core.

17. Oil Immersed Power Transformer –ESP Pump
Application
Example Specifications:
•Primary Voltage:400-600V
•Secondary Voltage:3000V-5000V (depending on the ESP motor requirements)
•Power Rating:50 kVA to 2500 kVA, depending on the power requirements of the ESP system.
Operational Considerations:
1. Location:
The transformer is typically located on the surface, close to the power supply and control systems.
2. Protection:
Equipped with protective devices such as circuit breakers, surge protectors, and cooling systems to ensure safe and
reliable operation.
3. Maintenance:
Regular inspection and maintenance are crucial to ensure the longevity and efficiency of the transformer and the entire
ESP system.

18. Key Component of ESP Operation
Surface Power
Diesel Engine
Transformer
Synchronizer
PowerSave
VSD Panel / Control Systems
Junction Box

19. Switchgear
Synchronizer or Switchgear:
AnAutomatic Transfer Switch (ATS)is an electrical switch that automatically transfers power from the primary
source (usually utility power) to a secondary source (such as a backup generator) when it detects a power outage
or interruption in the primary source, that works as following
1.Unexpected Loss of Utility Power :
1.When there’s a sudden power outage due to equipment failure, the electricity from the utility company
down.
2.Prompt Detection by Your Generator:
1.The ATS senses the power interruption instantly.
3.Automatic Activation of Your Generator:
1.Within seconds, the ATS activates your home standby generator.
2.This ensures that your lights, appliances, and other essential devices continue to operate normally.
4.Seamless Restoration of Power:
1.While the generator supplies power, your home functions as usual.
2.Appliances, HVAC systems, and critical electronics remain operational.
5.Detection of Restored Utility Power:
1.When utility power is restored, the ATS detects the end of the outage.
2.It then switches off the generator, seamlessly transitioning back to the utility power source.
https://support.generac.com/s/article/What-Is-an-Automatic-Transfer-Switch-ATS

20. Configuration
Diesel
Engine
Power Grid

21. Key Component of ESP Operation
Surface Power
Diesel Engine
Transformer
Synchronizer
PowerSave
VSD Panel / Control Systems
Junction Box

22. Powersave
•Comply with IEEE 519 2014
•Input voltage range: 380V -480V AC
•Frequency range: 50Hz -60Hz
•Enclosure: NEMA4, NEMA3R, NEMA1
•Power factor improvement: up to 0.85
•Harmonic distortion reduction: up to 50%
Operating temperature range: -10°C to +50° C
•IP rating: IP54
Configuration
TheALENNTRONICSPowerSaveAP2S-82tobeconnected
toPowergridorGeneratorSetoninputside.
FieldProven
ThePowerSavehadbeeninstalledinIraqsince2018in
harshenvironmentandPT.SumateraGlobalEnergyin
Indonesiasince2022.

23. Key Component of ESP Operation
Surface Power
Diesel Engine
Transformer
Synchronizer
PowerSave
VSD Panel / Control Systems
Junction Box

24. VSD Panel
VSD, also known as aVariable Frequency Drive (VFD), is an electrical device used to
control the speed of an electric motor by adjusting the frequency and voltage supplied
to it.
VSDs are commonly used in ESP systems to optimize pump performance, improve
energy efficiency, and extend equipment lifespan
Function of VSD :
•Speed Control
•Energy Efficiency
•Soft Start
•Harmonic Mitigation

25. MCCB 3-
P 630A
Incoming
CONTACTOR
TESYS
VSD FRENIC SINEWAVE FILTER
INDUCTION MOTOR
INSIDE VSD PANEL
POWER CABLE
MODBUS/SERIAL
ETHERNET
PLC HMI

26. VSD Panel: PLC
Common Brand PLC in the Industry
•Allen Bradley
Software RS Logix
•Schneider
Software : Unity, ProWORX32 & EcostruxureMachine Expert
•Siemens
Software : Simatic
•Omron
Software : CX-Programmer
•Mitsubishi
Software:MelsoftSeries
•Wecon
Software : Wecon PLC Editor

27. Key Component of ESP Operation
Surface Power
Diesel Engine
Transformer
Synchronizer
PowerSave
VSD Panel / Control Systems
Junction Box

28. Junction Box
This component provides a connection point from
the main cable to the switchboard or VSD, the
Junction Box also protects against possible
explosions that occur due to gases that may be
carried out of the borehole by the main cable.

29. Surface Equipment
Fuel Tank capacity designed to load diesel generator
Diesel generator

30. Surface Equipment
VSD and Trafo
Satellite Dish as Communication Link

31. Surface Equipment
Junction Box

32. Thank you
Open for Discussion